USER MANUAL GLT80TDC. User manual for 24-42V Direct Current Compressor GLT80TDC

Transcription

1 USER MANUAL GLT80TDC User manual for 24-42V Direct Current Compressor GLT80TDC

2 INDEX 1. About the Product 2. Installation and application 3. Wiring and connections 4. The Serial Port Interface (SPI) 5. Operating voltage 6. Battery protection system 7. Setting up the speed 8. Programming the electronic driver 9. Protections and alarms 10. Compressor cooling 11. Technical data 12. Supply 1. About the product Many vehicles for transportation of goods or recreation, such as trucks, caravans, boats, cars, etc. are often equipped with cooling appliances and air conditioners. The compressors for such mobile applications must be designed to operate from a low voltage DC power supply. These compressors must also be compact in their dimensions, highly reliable and yield high performances. GLT80TDC is Cubigel Compressors s answer to the needs of users requiring comfort and reliability in their travelling, either on holidays, at work or in any other circumstance where a DC powered air conditioner is utilised. The GLT80TDC is designed to operate silently, efficiently and reliably even up to angles of tilt of 20º, and works with the environmentally friendly refrigerant R134a. Its design is based on Cubigel Compressors L series, which has been successfully present in the market since 1964, and has had sales of more than 200 million units. GLT80TDC is designed for capillary tube expansion and can be powered at 24 and 42V DC, and also at 12V with some restriction. Each unit is supplied with a dedicated electronic driver (FDC3), which features all the protections for both the battery and the driver itself, including the compressor motor. The driver automatically adjusts itself to the voltage of the power supply. Evaporating temperature range: -25ºC to +10ºC. Condensing temperature range: up to 65ºC. Pull-down peak: 70ºC. Ambient temperature range: -10 to 55ºC (65ºC at starting). In case of ambient temperature lower than 0ºC, an oil heater will be needed.

3 The electronic control unit FDC3 is supplied with the exclusive Serial Port Interface (SPI), featuring a RJ45 telephone type connector. SPI allows the electronic driver to be connected to a computer for programming purposes using the FxC programming package (hardware and software, provided by Cubigel Compressors under request), and allows the communication with an Electronic Integral Manager of the appliance (EIM), and making the compressor work in slave mode. FDC3 electronic driver includes Smart Speed as programming option, which is a plug-in system for automatically selfadapting compressor speed to current thermal load in refrigerating appliances. Smart Speed reduces number of thermostat cycles by minimizing compressor speed, enlarging on-time at every thermostat cycle, so that start/stop energy loses are substantially reduced. Lowest speed yields also highest evaporating temperature, and so highest C.O.P. and lowest energy consumption. Pull-down is done at maximum programmed speed, so pull-down time is very short with respect to fixed speed systems. No design parameters neither of the compressor nor the appliance are required to be programmed, so Smart Speed can be easily used in all appliances with no design efforts. FDC3 electronic driver includes Sleep and Sleep Energy Saving as programming option, which are plug-in systems specially conceived for mobile air conditioners avoiding any other electronic device. Sleep and Sleep Energy Saving make the air conditioner work for four hours since start-up. Sleep Energy Saving makes the compressor run at maximum programmed speed during the first hour, when highest cooling capacity is needed, and lowers progressively the compressor speed up to minimum velocity three hours later. Maximum comfort and minimum energy consumption are thus achieved. GLT80TDC starting capability is as low as 10 V under any balanced pressure; it also admits a certain remaining differential pressure when thermostat off-time is abnormally short. For improving even more the starting capability, FDC3 electronic driver can be programmed with a 3 minutes minimum thermostat off-time. The delay is a programming option which can be easily enabled by means of the FxC programming kit. FDC3 also includes a 1 second filter at the thermostat input to prevent the appliance from wrong operation due to typical micro switching produced by vibrations in those appliances that fit tilt switches at the thermostat circuit. So, analogical filtering is not needed.

4 2. Installation and application Maximum tilt angle The maximum tilt angle allowed in GLT80TDC compressor (stopped or running) in any of the 2 below mentioned recommended positions is 20º, and maximun tilt angle in the 2 below not recommended position is 15º. Apart from this If compressor has been stopped during a certain period of time with an inclination higher than 15º, it is strongly recomspecification, below diagrams show the recommended and not recommended positions while the compressor is running in the application. RECOMMENDED POSITIONS β max=20º NOT RECOMMENDED POSITIONS α max=15º Fig.1: Maximum tilt angle mended to not start up the compressor immediately after coming back to the correct position. We recommend waiting at least 30 minutes before starting up the compressor. Off-road applications GLT80TDC compressor is not designed for off-road mobile applications. If you are interested in this type of mobile applications, it has to be specifically approved by Cubigel Compressors.

5 3. Wiring and Connections General rules GLT80TDC must always be powered through the dedicated electronic driver FDC3, which is supplied with the compressor as a separate device. NEVER CONNECT THE COMPRESSOR HERMETIC PINS (FUSITE) TO THE TERMINALS OF A BATTERY OR ANY OTH- ER DC OR AC SOURCE DIRECTLY. DO NOT TRY TO FIT AN ELECTRONIC DRIVER OTHER THAN THE FDC3. THE COMPRESSOR WILL NOT OPERATE AND IRREVERSIBLE DAMAGE MAY OCCUR. The FDC3 driver is directly connected to the battery poles as well as to the compressor pins. It checks battery voltage and adjusts itself to the voltage value for proper compressor operation, or switches itself off if the battery voltage is not adequate. The driver also controls the compressor speed. ALWAYS RESPECT THE POLARITY OF THE BATTERY WITH THE POWER INPUT TERMINALS OF THE ELECTRONIC DRIVER The unit is protected against damage caused by wrong polarity of the supply. The compressor will not run correctly if it s wrongly connected. - NEGATIVE POWER INPUT TERMINAL OF THE ELEC- TRONIC DRIVER SHOULD BE EARTHED, TO THE CHASSIS OF THE VEHICLE AS WELL AS THE APPLIANCE FRAME* A FUSE MUST BE PLACED BETWEEN THE + POLE OF THE BATTERY OR DC POWER SUPPLY AND THE + POWER IN- PUT TERMINAL OF THE ELECTRONIC DRIVER* 12V SYSTEMS: 30A FUSE 24V SYSTEMS: 30A FUSE 42V SYSTEMS: 20A FUSE * In some special vehicles chassis is connected to + terminal of the battery instead of - terminal (positive reference systems). In such cases + should be understood as - and vice-versa. In systems powered by a variable DC source, the fuse should be selected following the rules above mentioned, considering the maximum voltage at the variable DC Source. Voltage drop in the power leads To avoid excessive voltage drop in the leads, their length and cross section must be related to the voltage supply as indicated in Table 1. Cross section Rated Operating Range mm V V V If any kind of connector or switch is placed between the battery poles and the power terminals of the electronic driver, its resistance should be less than 10mΩ. If the resistance is higher than 5mΩ, the maximum length of the wires indicated in Table 1 should be halved or the cross section doubled. In case of using a long cable to connect battery and electronic driver, it is recommended using a cable with low inductance. Table 1: Maximum length of leads (m)

6 Wiring Diagram The FDC3 electronic driver features a terminal board where all connections are made. The terminal lay out is described in Figure 2: 24 42V FUSE FDC3 ELECTRONIC DRIVER BATTERY BAT+ PC FAN+ FAN 12V T + 15V+ SPI ELECTRONIC INTEGRAL MANAGER ALARM SWITCHER THERMOSTAT ELECTROMECHANICAL OR ELECTRONIC CONTROL PANEL Fig.2: FDC3 wiring scheme Fig.3: Connection of FDC3 driver to the compressor 4. The serial port interface The electronic control unit FDC3 is supplied with the exclusive Serial Port Interface (SPI), featuring a RJ45 telephone type connector. This port allows the electronic driver to be connected to a computer for programming purposes using the FxC programming package (hardware and software) provided by Cubigel Compressors under request. Optionally, the SPI can be configured to: Install a LED to display the intervention of any alarm. Set up either the compressor speed or the battery protection level, through physical connections between IN1, IN2 and COM. Connect the electronic driver as slave to an Electronic Integral Manager of the appliance with serial communication capabilities (Rx, Tx and COM), to allow working with variable speed. SPI provides a 5 V output, limited to 25mA, to power up the EIM. TO PROGRAM THE ELECTRONIC FDC3 DRIVER BY MEANS OF THE FXC PROGRAMMING KIT THE FDC3 DRIVER MUST BE POWERED BY THE BATERY.

7 Figure 4 Shows the RJ45 male connector which can be plugged to the SPI and the usage of each terminal in it V / 25mA 2. Rx 3. IN1 4. COM 5. LED 6. IN2 7. Tx 8. EN Fig.4: SPI terminals 5. Operating voltage GLT80TDC is designed to operate in a wide range of DC voltages, supplied either by a battery or by any other kind of filtered DC power supply. DC VOLTAGE SUPPLY ALLOWED: 10V to 42.4V Functional modes Standard (Default): From the value of the applied voltage, the electronic driver automatically decides the rated voltage range of the supply. Three possible ranges are considered: 12 to 14V: actual voltage is below 17V 24 to 28V: actual voltage is within 17 and 33V 36 to 42V: actual voltage is within 33 and 42.4V Special (programming option): The compressor can be powered by a variable DC source as, for instance, a photovoltaic panel, in which the output voltage strongly depends on the intensity of sunlight radiation. In these special cases the driver should be programmed with rated, minimum and maximum voltages. These values should be within the allowable DC voltage power supply (10 V to 42.4V). Rated voltage and voltage limits are programmed by the appliance manufacturer by means of a PC connected through the serial port to the driver Serial Port Interface, using the FxC programming package provided by Cubigel Compressors under request.

8 6. Battery protection system There is a protection system for the battery that prevents the compressor from operating if the available voltage becomes too low. The battery protection level should be set up as following: By programming: Voltage limits for battery protection can be freely set, by the customer for every system (12-14V, 24-28V, 36-42V or special) by means of the serial port of a PC connected to the SPI port of the electronic driver using the FxC programming package provided by Cubigel Compressors under request. In that option cut-out and cut-in values must respect the rule defined by Table 2. Rated Cut-out (V) ΔV voltage range (V) min max min max ,0 12,0 1, ,0 26,0 2,0 3, ,0 40,0 2,0 3,0 Special 9,0 40,0 1,0 3,0 Table 2. Limits of battery protection parameters In Table 2, ΔV is the difference between cut-out and cut-in, that is, the cut-in value is the result of adding ΔV to the cut-out value. Externally, using COM, IN1 and IN2 of SPI: This option prevents from the possibility of setting up the speed externally using COM, IN1 and IN2 of SPI as defined in point 6. The external battery protection set up option must be previously programmed for external adjustment of the protection limits. Voltage limits are set up by means of a PC through its serial port connected to the electronic driver SPI. It can be done by the customer itself using the FxC programming package. The cut-out (battery voltage at which the driver stops operating) and the cut-in (battery voltage at which driver re-starts operation after a cut-off) values are set up by connecting the SPI connector terminals IN1 and IN2 to COM. Cubigel Compressors according to the connection made, four protection levels can be selected as shown in Table 3. Protection limits (V) Rated operating voltage range Protection level Connection to COM V V V IN1 IN2 cut-out cut-in cut-out cut-in cut-out cut-in Standard ,0 11,5 22,0 24,5 36,0 38,5 Low 1 0 9,0 10,5 20,0 22,5 34,0 36,5 High ,0 12,5 24,0 26,5 38,0 40,5 Very high ,0 13,5 26,0 28,5 40,0 42,5 Table 3. IN1, IN2 and COM connection for battery protection set up 0=open connection; 1=shortened

9 7. Setting up the speed It is possible to operate the compressor at fixed or variable speed under different running modes, options and parameters. The electronic driver is supplied by Cubigel Compressors with standard running mode and external control of the speed, with minimum speed of 2,000 rpm. and maximum speed 3,500 rpm. Default running mode, options and parameters can be changed to optimize compressor performance for a given appliance, by programming, connecting a PC to the SPI by means of the FxC programming package provided by Cubigel Compressors under request. Running modes and options are: Standard mode: Compressor speed is a fixed programmed value or switched externally from programmed minimum and maximum value in four steps. The switch should be connected to the SPI and should remain plugged during compressor operation. When setting up a fixed speed, maximum speed can be limited by the available battery voltage in the following way, maximum speed would be: 2,000 rpm when the battery voltage is equal to the cut-in voltage. Programmed fixed speed when the battery voltage is equal to or greater than the maximum nominal voltage (14V, 28V and 42V for 12V, 24V and 42V systems respectively). A linear function of the battery voltage in the range between the cut-in and the maximum nominal voltages. This option is particularly useful for eutectic plates systems. If external switching is programmed, the speed is set up by the connection of the SPI connector terminals IN1 and IN2 to COM for minimum, maximum speeds, and two intermediate velocities Cubigel Compressors according to Table 4: Connection to COM Speed of the motors (rpm) IN1 IN2 0 0 Smin 1 0 Smin+1/3 (Smax-Smin) 0 1 Smin+2/3 (Smax-Smin) 1 1 Smax Table 4. External selection of the velocity 0=Open connection 1=Shortened External speed set up option must be previously programmed for external adjustment of its minimum (Smin) and maximum (Smax) limits. External switching prevents from the possibility of setting up the battery protection externally using COM, IN1 and IN2 of SPI as defined in point 5. Smart Speed mode: Compressor will run at variable speed at its highest performance depending of the current thermal load. The speed can be limited by a fixed programmed value and even more by the available battery voltage as described in standard mode. The speed can also be limited by external switching in the same way as described in standard mode.

10 NO SWITCH (MANUAL I/O, TILT, ETC.) IS ALLOWED TO BE CONNECTED IN SERIES WITH THE THERMOSTAT. IF ELECTRONIC THERMOSTATS ARE TO BE FIT, AVOID THOSE THAT INCORPORATE MANUAL I/O SWITCH AND/OR STARTING DELAY. Sleep mode: Compressor will run during four hours after start-up. The speed can be limited by a fixed programmed value and even more by the available battery voltage as described in standard mode. The speed can also be limited by external switching in a similar way as described in standard mode, Cubigel Compressors according to table 5: Connection to COM IN1 IN2 Speed of the motors (rpm) Sleep mode 0 0 S min off 1 0 S min on 0 1 S max off 1 1 S max on If off sleep mode is selected, the appliance will run continuously at selected fixed speed S min or S max. Sleep Energy Saving mode: Compressor will run during four hours. During first hour compressor will run at selected speed. During next three hours speed will decrease up to 2,000 r.p.m. Programming Sleep Energy Saving is done in the same way as Sleep. Slave mode: Under this mode, variable speed is controlled by an Electronic Integral Manager of the appliance (EIM) permanently connected to the electronic driver FDC3 through the SPI, using its serial communication capability. The EIM reads the current temperature inside the appliance, compares it with the set point temperature, and decides if the compressor should operate or not, and if so, at which speed. The EIM communicates how the compressor should operate and, eventually, records and displays any abnormal circumstance that might occur. For details about the communication protocol, please, contact Cubigel Compressors. Table 5. External selection of the velocity 0=Open connection; 1=Shortened IF ANY VARIABLE SPEED MODE IS TO BE PROGRAMMED, CHECK CAREFULLY FOR TUBES, CONDENSER AND EVAP- ORATOR RESONANCES. NATURAL FREQUENCIES SHOULD BE 75 Hz UP TO AVOID VIBRATIONS.

11 8. Programming the electronic driver In order to program the electronic driver FDC3, a personal computer together with the FxC programming package are required (provided by Cubigel Compressors under request). To this purpose, perform the following steps: 1. Install the programming software, following the instructions of the wizard. 2. Connect the programming interface to a PC using the serial cable supplied with the hardware. 3. Power on the programming interface using the AC/DC adapter supplied with the hardware. 4. Connect the FDC3 electronic driver to the programming interface using the double RJ45 cable supplied with the hardware. 5. Run the programming file FDC.exe. 6. From the top menu, load an existing configuration and go to step 9, or go through step 7. Select the running mode, options and parameters, between: 7.1 Standard mode Select maximum fixed speed and enter a value within 2,000 and 3,500 r.p.m. as described in point 6, if desired select speed limited by available battery voltage, or Select external switcher connected to SPI and enter low and high speed values within 2,000 and 3,500 r.p.m. as described in point 6. External speed selection is incompatible with external battery protection (step 8.2). 7.2 Smart Speed mode. Select maximum fixed speed or external switcher connected to SPI and proceed as described in or respectively. 7.3 Sleep and Sleep Energy saving modes. Select maximum fixed speed or external switcher connected to SPI and proceed as described in or respectively. 7.4 Slave mode 8. Select the battery protection mode and the protection parameters from: 8.1 Internal protection: choose between normal and special voltage systems For normal voltage systems, enter cut-out, cut-in and maximum voltage values for every voltage system, Cubigel Compressors accounting for the limits shown in Table 2 of point For special voltage systems, enter cut-out, cut-in and nominal and maximum voltage values Cubigel Compressors accounting for the limits shown in Table 2 of point External protection. Protection values are shown in Table 3 of point 5. External protection is incompatible with external speed selection (step 7.2). 9. Select thermostat delay 3 minutes for improved starting. 10. Click Apply. The FDC3 electronic driver is now programmed and ready to drive the compressor. 11. From the top menu, save the current configuration if desired. 12. To program another FDC3 unit, plug it in, apply current configuration or return to step 6 to change configuration. 13. Click exit to finish.

12 9. Protections and alarms GLT80TDC is electronically protected against a number of possible malfunctions and failures: Battery discharge: refer to point 5 for details. Fan over current: protects the compressor and the electronic driver against fan over current due to start or running overload, or short-circuit. Starting failure: if the running speed is not achieved during the starting sequence, the unit stops and retries the start up after one minute. Compressor overload: This protection operates when the compressor speed drops below the set up speed, or when the current drawn in is excessive, thus preventing the appliance from operating under overload conditions, causing refrigerating overload or compressor failure. Electronic driver overheat: In case the temperature of the electronic components of the control becomes too high, an internal sensor will stop the unit. When the alarm is on, ten automatic attempts to restart the compressor will be available. In case of battery protection, the number of automatic attempts to restart is unlimited. Once the sequence of automatic attempts to restart the compressor is finished, the unit will remain permanently unable to operate until it is switched off and on again from the power supply. The intervention of the thermostat during the sequence of automatic restart attempts interrupts and resets the sequence. The SPI can be configured in a way that a LED can be connected between terminals 3 and 4 (see Fig. 2 in point 3) in order to display the intervention of any alarm, and to identify its cause. The visualisation consists of a sequence of flashes of the LED repeating every 5 seconds, until the cause of the alarm disappears. The code of the flashing sequence corresponding to each alarm is indicated in Table 6: No. of flashes Type of fallure 1 battery protection 2 fan over current 3 starting failure 4 compressor overload 5 electronic driver overheat 7 internal error Table 6. Alarm codification In case of an alarm display, if the FDC3 electronic driver is connected as a slave to the appliance s Electronic Integral Manager (EIM) through the SPI, a digital alarm code will be transmitted to the EIM, which in turn will manage the information for displaying and acting purposes.

13 10. Compressor Cooling GLT80TDC should always be fan cooled. FDC3 electronic driver has its own fan to cool its power components, but enough fresh air is needed in the surroundings of the electronic driver to be cooled properly. Best results are obtained when both compressor and driver are cooled with fresh air coming directly from outside, before being heated up in appliance condenser. 11. Technical Data Compressor Displacement cm Diameter mm Stroke mm 17,48 Net weight kg 10.2 Oil type ISO VG 22 ESTER Oil charge cm Reliability GLT80TDC pass following reliability tests: High Temperature: Cubigel Compressors according with CECOMAF GT-4002 standard Wear: Cubigel Compressors according with CECOMAF GT-4003 standard ON/OFF: Cubigel Compressors according with CECOMAF GT-4004 standard Vibrations: Cubigel Compressors according with ASTM 5728 Level I standard Application Application MBP-HBP-A/C Refrigerant R134a Evaporation temp. range ºC -25 to +10 Expansion system CAPILLARY Compressor cooling Fan Max. ambient temperature ºC 43 Electrical Voltage V DC 12 to 42 Voltage range V DC 10 to 42.4 Motor Type Brush-less, Sensor-less, PMM Phase number 3 Pole number 6 Locked rotor current (12, 24, 42 V) A 12, 12, 8 Resistance at 25ºC (R-S/R-T/S-T) Ω 0.36

14 Electronic driver Model Type Supported devices Communication port Communication capabilities Compressor speed selection Battery protection level selection Protections Programmable running modes Default settings FDC3 Fully digital & programmable, μp based 12V/1A Fan Compressor speed or battery protection level switcher Alarm LED 15V/25mA electronic thermostat 5V/25mA Electronic Integral Manager Serial Port Interface (SPI) RS-232 serial port 2-digit, 4-level switcher Alarm LED By programming or switching* By Programming or switching* *only one at a time Battery protection Fan over current Starting failure Compressor overload Electronic driver overheat Fan over current Starting failure Compressor overload Electronic driver overheat Standard Smart Speed Sleep Sleep Energy Saving Slave Running mode: Standard Speed selection: external switcher Lower/higher speed: 2000/3500 r.p.m. Battery protection: fixed voltage level; standard system Cut-out (12/24/42 V systems): 12/22/38,2 V Cut- in (12/24/42 V systems): 10.8/20/36.2 V 3 minutes thermostat delay: off Nominal performance at rpm * 3000* 3500* Cooling capacity W Cooling capacity kcal/h Input power W EER kcal/(wh) , COP W/W ,26 2,17 2,07 Current A Test Conditions Evaporating temperature ºC +7.2 Condensing temperature ºC 55 Subcooling K 9 Ambient and return temp. ºC 35 Voltage Test V DC 24 *Only for voltage supply: V DC 24-42

15 Fig.5: GLT80TDC outline drawing Performance data r.p.m. T evap = -25ºC T evap = -10ºC T evap = +7,2ºC Q (kcal/h) COP Q (kcal/h) COP Q (kcal/h) COP 2, , * 2.26* 3, * 1.58* 725* 2.17* 3, * 1.54* 834* 2.07* r.p.m. T evap = -25ºC T evap = -10ºC T evap = +7,2ºC W I (A) W I (A) W I (A) 2, , * 13.1* 3, * 10.5* 388* 16.2* 3, * 12.3* 468* 19.5* Condensing temperature = 55ºC Ambient and suction temperature = 35ºC Liquid subcooling = 9K Test voltage = 24V DC *Only for V DC voltage supply 12. Supply GLT80TDC compressor including FDC3 electronic driver (120 pieces pallets).

16 07/2013 Huayi Compressor Barcelona, S.L. Antoni Forrellad, Sant Quirze del Vallès BCN Spain Phone: Fax